Voxel and stereolithographic digital design framework in additive manufacturing: effects in a PolyJet printing process and relevant digital solutions

2021 ◽  
Author(s):  
Furkan I. Ulu ◽  
Ram V. Mohan
Keyword(s):  
Additive Manufacturing ◽  
Digital Design ◽  
Design Framework ◽  
Printing Process ◽  
Polyjet Printing

Processing and mechanical behavior of rigid and flexible material composite systems formed via voxel digital design in polyjet additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Furkan Ulu ◽  
Ravi Pratap Singh Tomar ◽  
Ram Mohan
Keyword(s):  
Mechanical Properties ◽  
Composite Material ◽  
Additive Manufacturing ◽  
Mechanical Behavior ◽  
Digital Design ◽  
Composite Part ◽  
Content Type ◽  
Composite Systems ◽  
Polyjet Printing ◽  
Material Composite

Purpose PolyJet technology allows printing complex multi-material composite configurations using Voxel digital designs' capability, thus allowing rapid prototyping of 3D printed structural parts. This paper aims to investigate the processing and mechanical characteristics of composite material configurations formed from soft and hard materials with different distributions and sizes via voxel digital print design. Design/methodology/approach Voxels are extruded representations of pixels and represent different material information similar to each pixel representing colors in digital images. Each geometric region of a digitally designed part represented by a voxel can be printed with a different material. Multi-material composite part configurations were formed and rapidly prototyped using a PolyJet printer Stratasys J750. A design of experiments composite part configuration of a soft material (Tango Plus) within a hard material matrix (Vero Black) was studied. Composite structures with different hard and soft material distributions, but at the same volume fractions of hard and soft materials, were rapidly prototyped via PolyJet printing through developed Voxel digital printing designs. The tensile behavior of these formed composite material configurations was studied. Findings Processing and mechanical behavior characteristics depend on materials in different regions and their distributions. Tensile characterization obtained the fracture energy, tensile strength, modulus and failure strength of different hard-soft composite systems. Mechanical properties and behavior of all different composite material systems are compared. Practical implications Tensile characteristics correlate to digital voxel designs that play a critical role in additive manufacturing, in addition to the formed material composition and distributions. Originality/value Results clearly indicate that multi-material composite systems with various tensile mechanical properties could be created using voxel printing by engineering the design of material distributions, and sizes. The important parameters such as inclusion size and distribution can easily be controlled within all slices via voxel digital designs in PolyJet printing. Therefore, engineers and designers can manipulate entire morphology and material at each voxel level, and different prototype morphologies can be created with the same voxel digital design. In addition, difficulties from AM process with voxel printing for such material designs is addressed, and effective digital solutions were used for successful prototypes. Some of these difficulties are extra support material or printing the part with different dimension than it designed to achieve the final part dimension fidelity. Present work addressed and resolved such issued and provided cyber based software solutions using CAD and voxel discretization. All these increase broad adaptability of PolyJet AM in industry for prototyping and end-use.

Reconfigurable molds and a fabrication-aware design tool for manufacturing concrete grid structures

2021 ◽  
pp. 147807712110300
Author(s):  
Ali Baghi ◽  
Saleh Kalantari ◽  
Aryan Baghi
Keyword(s):  
Additive Manufacturing ◽  
Casting Machine ◽  
Design Tool ◽  
Digital Design ◽  
Architectural Geometry ◽  
Current Trends ◽  
Design And Manufacturing ◽  
Concrete Joints ◽  
Concrete Casting ◽  
Concrete Elements

The design and manufacturing of concrete elements need to be reconsidered in light of current trends in architectural geometry. Today, there is a movement toward greater customization and adaptability of concrete elements using “reconfigurable formworks” and “additive manufacturing.” Our study approached the issue of fabricating non-standardized concrete elements from the perspective of a “reconfigurable fabrication platform.” Specifically, we developed a method of fabricating geometrically diverse concrete joints by combining flexible pressure-enduring tubes with a rigid mechanism, resulting in an adaptive concrete-casting machine. This platform, which we named “Flexi-node,” can be used in conjunction with a relevant fabrication-aware digital design tool. Users can computationally design and fabricate a great variety of concrete joints using just one mold, with a minimum of material waste and with no distortion from hydrostatic pressure as would typically occur in a fully flexible formwork.

scholarly journals Digital design and nonlinear simulation for additive manufacturing of soft lattice structures

2019 ◽  
Vol 25 ◽  
pp. 39-49 ◽  
Author(s):  
O. Weeger ◽  
N. Boddeti ◽  
S.-K. Yeung ◽  
S. Kaijima ◽  
M.L. Dunn
Keyword(s):  
Additive Manufacturing ◽  
Digital Design ◽  
Lattice Structures ◽  
Nonlinear Simulation

A Design and Fabrication Framework for Periodic Lattice-Based Cellular Structures in Additive Manufacturing

2015 ◽  
Author(s):  
Recep M. Gorguluarslan ◽  
Umesh N. Gandhi ◽  
Raghuram Mandapati ◽  
Seung-Kyum Choi
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Cellular Structures ◽  
Periodic Lattice ◽  
Design Framework ◽  
Finite Element Study ◽  
Linear Finite Element ◽  
Non Linear ◽  
3D Printed ◽  
Element Study

A design framework that incorporates a size optimization algorithm is proposed for periodic lattice-based cellular structures fabricated by additive manufacturing. A 3D modeling process for the lattice-based cellular structures is integrated into the design framework for non-linear finite element analysis (FEA) and production. Material properties for the 3D printed parts are determined for the finite element study using reverse engineering of actual measured data. The lattice layout that will be used in the optimization is selected and the size of the cross sections is optimized using in-house optimization approach for both yield and local buckling criteria. The 3D model for the optimized lattice structure is built and non-linear finite element study is conducted to predict the performance. The approach is demonstrated on a compression block with periodic lattice-based unit cells. Physical parts are 3D printed and tested to compare with the simulations.

scholarly journals A design framework for additive manufacturing

2019 ◽  
Vol 103 (9-12) ◽  
pp. 3769-3783 ◽  
Author(s):  
H. Bikas ◽  
A. K. Lianos ◽  
P. Stavropoulos
Keyword(s):  
Additive Manufacturing ◽  
Design Framework

scholarly journals ANIMATED ADDITIVE MANUFACTURING Designing Dynamic Exhibits with 3D Printing & Pixel Displays

2021 ◽  
Author(s):  
◽  
Lakjith Manapaya Weeratunge
Keyword(s):  
Additive Manufacturing ◽  
Video Games ◽  
3D Printing ◽  
Digital Information ◽  
Complex Motion ◽  
High Demand ◽  
Printing Process ◽  
Wear And Tear ◽  
Display Technology ◽  
Realistic Images

<p>Physical moving parts are prone to wear and tear. A pixel display can manifest complex motion and realistic images in full colour offering a form of tangibly while being less likely to suffer from wear and tear however, it remains restricted to 2D surfaces. The recent development in voxel-based printing (voxel = 3D pixel) allows multi-material and multi-colour 3D printing to transform images into physical objects. However, during the printing process the capacity to change the pixels colour and position in the future are lost, effectively fusing the digital information. The high demand for immersive experiences in video games, films, museums and interactive products are omnipresent. The combination of pixel display technology and multi-material 3D printing is a potential avenue to create immersive experiences to feed this high demand.</p>

scholarly journals Comparison between Tests and Simulations Regarding Bending Resistance of 3D Printed PLA Structures

Polymers ◽  
2021 ◽  
Vol 13 (24) ◽  
pp. 4371
Author(s):  
Dorin-Ioan Catana ◽  
Mihai-Alin Pop ◽  
Denisa-Iulia Brus
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
3D Printing ◽  
Process Parameters ◽  
Bending Stress ◽  
Test Results ◽  
Printing Process ◽  
Simulation Process ◽  
Bending Resistance ◽  
3D Printed

Additive manufacturing is one of the technologies that is beginning to be used in new fields of parts production, but it is also a technology that is constantly evolving, due to the advances made by researchers and printing equipment. The paper presents how, by using the simulation process, the geometry of the 3D printed structures from PLA and PLA-Glass was optimized at the bending stress. The optimization aimed to reduce the consumption of filament (material) simultaneously with an increase in the bending resistance. In addition, this paper demonstrates that the simulation process can only be applied with good results to 3D printed structures when their mechanical properties are known. The inconsistency of printing process parameters makes the 3D printed structures not homogeneous and, consequently, the occurrence of errors between the test results and those of simulations become natural and acceptable. The mechanical properties depend on the values of the printing process parameters and the printing equipment because, in the case of 3D printing, it is necessary for each combination of parameters to determine their mechanical properties through specific tests.

Digital Design Automation to Support In-Situ Embedding of Functional Components in Additive Manufacturing

2019 ◽  
Author(s):  
Manoj Malviya ◽  
Swapnil Sinha ◽  
Nicholas A. Meisel
Keyword(s):  
Additive Manufacturing ◽  
Digital Design ◽  
Design Knowledge ◽  
Print Quality ◽  
Test Cases ◽  
Entire Volume ◽  
Cross Section Area ◽  
Functional Components ◽  
In Situ Embedding

Abstract Additive manufacturing (AM) offers access to the entire volume of a printed artifact during the build operation. This makes it possible to embedding foreign components (e.g. sensors, motors, actuators) into AM parts, thus enabling multifunctional products directly from the build tray. However, the process of designing for embedding currently requires extensive designer expertise in AM. Current methods rely on a designer to select an orientation for the embedded component and design a cavity such that the component can be successfully embedded without compromising the print quality of the final part. For irregular geometries, additional design knowledge is required to prepare a shape converter: a secondary piece to ensure a flush deposition surface on top of the embedded component. This research aims to develop a tool to automate these different design decisions for in-situ embedding, thus reducing the need for expert design knowledge. A three-stage process is proposed to 1) find the optimum orientation based on cavity volume and cross-section area, 2) create the necessary cavity geometry to successfully insert the component, and 3) perform a Boolean operation to create the digital design for any requisite shape converter. Performance of the tool is demonstrated with four test cases with varying levels of geometric complexity. These test cases show that the proposed process successfully handles arbitrary embedded geometries, though several limitations are noted for future work.

Dimensional Accuracy in PolyJet Printing: A Literature Review

2019 ◽  
Author(s):  
Ketan Thakare ◽  
Xingjian Wei ◽  
Zhijian Pei
Keyword(s):  
Additive Manufacturing ◽  
Layer Thickness ◽  
Surface Finish ◽  
Dimensional Accuracy ◽  
High Dimensional ◽  
Control Variables ◽  
Current Trends ◽  
Manufacturing Methods ◽  
Polyjet Printing ◽  
Part Orientation

Abstract PolyJet printing process is one of the additive manufacturing methods to print parts with high dimensional accuracy. To date, dimensional accuracies of such process have been investigated by a number of studies. This review will summarize those studies, and identify current trends. With respect to methods of measurements used in the reported studies, it is noted that no special preference is given to use of any method. In addition, the effects of four control variables of PolyJet process: part orientation, layer thickness, surface finish type and materials, on dimensional accuracy are noted based on the results of reported studies. There is consistency in results in studies considering control variables of layer thickness, surface finish type and materials. However, the results are inconsistent in studies considering part orientation.

scholarly journals Cumulative Inaccuracies in Implementation of Additive Manufacturing Through Medical Imaging, 3D Thresholding, and 3D Modeling: A Case Study for an End-Use Implant

2020 ◽  
Vol 10 (8) ◽  
pp. 2968 ◽  
Author(s):  
Jan Sher Akmal ◽  
Mika Salmi ◽  
Björn Hemming ◽  
Linus Teir ◽  
Anni Suomalainen ◽  
...  
Keyword(s):  
Computed Tomography ◽  
Additive Manufacturing ◽  
Medical Imaging ◽  
3D Modeling ◽  
Computer Aided Design ◽  
Digital Design ◽  
Worst Case ◽  
Custom Made ◽  
End Use

In craniomaxillofacial surgical procedures, an emerging practice adopts the preoperative virtual planning that uses medical imaging (computed tomography), 3D thresholding (segmentation), 3D modeling (digital design), and additive manufacturing (3D printing) for the procurement of an end-use implant. The objective of this case study was to evaluate the cumulative spatial inaccuracies arising from each step of the process chain when various computed tomography protocols and thresholding values were independently changed. A custom-made quality assurance instrument (Phantom) was used to evaluate the medical imaging error. A sus domesticus (domestic pig) head was analyzed to determine the 3D thresholding error. The 3D modeling error was estimated from the computer-aided design software. Finally, the end-use implant was used to evaluate the additive manufacturing error. The results were verified using accurate measurement instruments and techniques. A worst-case cumulative error of 1.7 mm (3.0%) was estimated for one boundary condition and 2.3 mm (4.1%) for two boundary conditions considering the maximum length (56.9 mm) of the end-use implant. Uncertainty from the clinical imaging to the end-use implant was 0.8 mm (1.4%). This study helps practitioners establish and corroborate surgical practices that are within the bounds of an appropriate accuracy for clinical treatment and restoration.

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